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Advanced Technology
& Capabilities

Powered by world-class equipment, precision engineering software, and continuous R&D investment — our technology stack sets a new benchmark for aluminum manufacturing.

Manufacturing Intelligence

Where Precision
Meets Power

HydroMetal operates one of the most advanced aluminum manufacturing facilities in the region, combining high-tonnage extrusion technology with digital engineering tools and real-time quality systems.

Every step of our production cycle — from billet heating to final inspection — is governed by process controls designed to eliminate variance and guarantee repeatability at scale.

Industry 4.0-enabled production monitoring
Automated dimensional inspection systems
Integrated ERP & quality management platform
Manufacturing
Core Capabilities

Technical Specifications

High-Tonnage Extrusion Presses

Our press fleet includes 8-inch and 10-inch container presses ranging from 1,100 to 2,800 metric tonnes, capable of producing profiles from the simplest solid shapes to complex multi-void hollow sections.

Max Press Force2,800 MT
Container SizeUp to 10 inch
Alloys Supported6000 & 7000 Series

Precision CNC Tooling Center

Our in-house CNC milling and turning centers handle complete die and mold fabrication from raw steel to finished tooling. Dimensional accuracy is held to ±0.005mm across all critical features.

Tolerance±0.005 mm
MaterialH11 / H13 Tool Steel
Surface FinishRa 0.4 µm

Anodizing & Surface Treatment Plant

Our dedicated anodizing facility handles Type II and Type III hard anodizing with full color capability. The sulfuric acid anodizing line processes up to 6-meter profiles with consistent coating thickness control.

Max Profile Length6,000 mm
Coating Thickness10–25 µm
TypesType II & Type III

Real-Time Quality Control Systems

Integrated CMM (Coordinate Measuring Machine) inspection, automated optical profiling, and spectrometric alloy analysis ensure every batch meets specification before leaving our facility.

Inspection MethodCMM + Optical
Sample Rate100% critical dims
Alloy AnalysisOES Spectrometry

Cylinder Casting & Boring

Dedicated casting furnaces and precision horizontal boring machines allow production of hydraulic-grade aluminum cylinders with ultra-smooth internal bores and close-tolerance outer diameters.

Bore ToleranceH7 class fit
Max Diameter500 mm
Surface HoningRa ≤ 0.8 µm

Billet Casting & Heat Treatment

Continuous casting furnaces produce billets of controlled composition, followed by homogenization heat treatment ovens that optimize the alloy microstructure for superior extrusion performance.

Billet Diameter203–254 mm
Homogenizing560–580 °C
Casting RateUp to 4 T/hr
Production Fleet

Key Equipment

01

2,800T Direct Hydraulic Extrusion Press

Largest press in our fleet — handles complex hollow profiles up to 250mm circle size

Primary Line
02

1,650T Indirect Extrusion Press

Optimized for thin-wall precision profiles with minimal billet skin contamination

Secondary Line
03

5-Axis CNC Machining Center (FANUC)

Complete die and mold fabrication with sub-micron positional repeatability

Tooling Shop
04

ZEISS CMM Coordinate Measuring Machine

3D dimensional verification of complex profiles to ±0.003mm accuracy

QC Lab
05

Oxford OES Optical Emission Spectrometer

Real-time alloy chemistry verification on every billet and finished product

Materials Lab
06

6-Zone Pusher Homogenizing Furnace

Uniform temperature homogenization across 6-meter billet loads for optimal alloy microstructure

Casting Plant
Engineering Software

Design & Simulation Tools

CAD Design

SolidWorks

3D parametric CAD modeling for die design and profile engineering

FEA Simulation

ANSYS

Finite element analysis for structural validation and thermal simulation

Extrusion Simulation

QForm Extrusion

Metal flow simulation for die optimization before physical tooling

CAM Programming

Mastercam

Full 5-axis CNC toolpath programming for complex die geometries

Quality Systems

ZEISS Calypso

CMM measurement programming and GD&T analysis reporting

ERP & Production

SAP S/4HANA

Integrated ERP for production planning, inventory, and order management

3D Scanning

GOM ATOS

Structured-light 3D scanning for reverse engineering and first-article inspection

Process Control

LabVIEW / SCADA

Real-time process monitoring and control across all production equipment

Quality Assurance

Certifications & Standards

ISO 9001:2015

Quality Management System certification covering the full manufacturing process from design to delivery.

ISO 14001:2015

Environmental Management System — ensuring our operations meet rigorous global environmental performance standards.

EN 755 / EN 12020

European standard compliance for extruded aluminum alloy profiles — dimensional tolerances and mechanical property requirements.

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Demanding Solution?

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